Distribution valve monitor and distribution valve incorporating same

ABSTRACT

A distribution valve monitor to monitor the operation of a distribution valve of the type having an inlet and a plurality of outlets, which couples the outlets to the inlet according to a desired fluid distribution pattern comprises a plurality of non-contact sensors disposed at spaced locations about the distribution valve to sense activation of the valve to different operating conditions. A controller communicates with the sensors and records data representing the operation of the valve. The recorded data is examined to detect improper operation of the distribution valve.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a continuation of U.S. patent applicationSer. No. 11/122,791 filed May 4, 2005 which in turn claims the benefitof U.S. provisional patent application No. 60/568,427 filed on May 4,2004, both of which are hereby incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates generally to valve diagnostics and inparticular to a distribution valve monitor and to a distribution valveincorporating the same.

BACKGROUND OF THE INVENTION

Distribution valves are known in the art and have been used in bothirrigation and wastewater treatment systems to allow fluid to beeffectively distributed over large areas. One common mechanical liquiddistribution valve (MLDV) is manufactured by K-Rain Corporation ofFlorida. This MLDV includes an enclosure having a single inlet and aplurality of outlets, typically four (4), five (5) or six (6). A plungeris centrally disposed within the enclosure and is secured to a rubberplate that can be moved to seat against the valve bottom. The plate hasan aperture therein that aligns with one of the outlets. The plungeraccommodates a spring element that acts on the plate to force it awayfrom valve bottom. When fluid under pressure is supplied to the inlet,the force of the fluid moves the plunger down through a cam causing theplunger and plate to rotate and seat the plate against the valve bottomwith the aperture in the plate in alignment with one of the outlets.When the fluid pressure supplied to the inlet drops, the plate andplunger are biased back upwardly thereby moving the plunger back throughthe cam and causing the plunger and plate to rotate. When fluid underpressure is again supplied to the inlet, the plunger and plate movedownwardly against the spring bias and rotate thereby to seat the plateagainst the valve bottom with the aperture in the plate in alignmentwith the next outlet. Cycling fluid pressure to the MLDV in this mannertherefore allows the incoming fluid to be distributed to the outlets ofthe MLDV in succession.

FIG. 1 shows a conventional arrangement for an MLDV 10. As can be seen,the MLDV 10 includes an inlet 12 connected to a pump 14 via a conduit16. The pump 14 draws fluid from a fluid source such as a reservoir ortank 18 via a conduit 20. The pump 14 is operated to cyclically supplyfluid under pressure to the inlet 12 of the MLDV 10 at intervals. Theoutlets 24 of the MLDV 10 are connected to a plurality of dischargepoints 26 positioned at different zones by conduits 28. During typicaloperation, the MLDV 10 couples the outlets 24 to the inlet 12 insuccession so that fluid flow to the discharge points 26 cycles througha desired pattern allowing the fluid to be effectively distributed.

Although MLDVs serve a valuable and useful purpose, they are subject tofailure and/or improper operation. Over time, MLDVs can be wornresulting in failure. Rocks or other debris may become lodged in theMLDV internal mechanisms thereby preventing the MLDVs from movingthrough their cycles. Installation errors may also result in improperMLDV operation. Furthermore, sub-optimal pump timing, freezing,insufficient fluid flow or inadequate fluid pressure and/or air in theconduits may result in inconsistent MLDV operation and skipping.

Regardless of the environment in which MLDVs are being used, it isimportant for the MLDVs to operate properly so that fluid is applieduniformly throughout the various zones. Failure to do so can beproblematic. In irrigation systems, failure of MLDVs may result in zonesbeing supplied with excess or insufficient water. In farmingenvironments, excess water in any particular zone may reduce crop yieldsdue to leaching of plant nutrients, increase disease incidence and/orfail to stimulate growth of commercially valuable parts of crops.Insufficient watering in any particular zone may lead to high soilmoisture tension that creates plant stress and reduces crop yield. Inother environments such as for example on golf courses where MLDVs areused to distribute water to greens, failure or skipping of the MLDVs mayresult in extensive damage.

When used in wastewater treatment and/or disposal systems, failure ofMLDVs is of even more concern due to the potential environmental impactresulting from such a failure. Even distribution of treated effluentacross dispersal zones is essential to ensure that the treated effluentis naturally absorbed into the environment. In wastewater treatmentsystems employing filter media such as for example, soils, textilefilters etc., if the filter media is overloaded, its ability to treateffluent may be adversely affected potentially resulting in seriousenvironmental problems including groundwater contamination andsurfacing/breakout of untreated effluent.

Unfortunately, to-date there has been no convenient way of determiningwhether MLDVs are operating properly. Presently, in order to determineproper MLDV operation, it is necessary to visually inspect each MLDV.During inspection, the system must be partially dismantled so that theMLDV can be cycled by manually turning the inlet fluid pressure on andoff and visually monitoring the fluid output of the MLDV. As will beappreciated, inspecting MLDVs in this manner is time consuming andimpractical especially in systems employing significant numbers ofMLDVs. As a result, there is a need for improved methods of monitoringMLDV operation.

It is therefore an object of the present invention to provide a noveldistribution valve monitor and a novel distribution valve incorporatingthe same.

SUMMARY OF THE INVENTION

According to one aspect, there is provided a distribution valve monitorto monitor the operation of a distribution valve of the type having aninlet and a plurality of outlets, which couples the outlets to the inletaccording to a desired fluid distribution pattern. The monitor includesa plurality of non-contact sensors disposed at spaced location about thedistribution valve to sense activation of the valve to differentoperating conditions. A controller communicates with the sensors andrecords data representing the operation of the distribution valve. Therecorded data is examined to detect improper operation and/or failure ofthe valve.

In one embodiment, an alarm signal is generated when the controllerdetermines that the operation of the valve has been significantlycompromised i.e. the valve has jammed or skips. The sensors are halleffect sensors and detect the presence of magnets disposed within thevalve as the magnets move during cycling of the valve. The sensorsinclude a plunger sensor to sense reciprocation of a plunger within thedistribution valve and rotation sensors to sense rotation of a platewithin the distribution valve. A magnet is disposed on the plunger andon the plate. The distribution valve monitor can be retrofitted to anexisting distribution valve or incorporated into the distribution valvethereby to form an integrated unit.

In one embodiment, the sensors and controller are accommodated within anenclosure. The enclosure is shaped to receive the distribution valve.The distribution valve monitor may include a user interface having adisplay to enable recorded data and/or distribution valve operation datato be visually presented. The controller compares recorded data withdesired distribution valve operating data to detect improperdistribution valve operation. The desired distribution valve operatingdata may be programmable. The distribution valve monitor may furthercomprise an interface to enable recorded distribution valve operationdata to be downloaded to a remote location.

According to another aspect there is provided a distribution valvemonitor to monitor the operation of a distribution valve of the typehaving at least one inlet, a plurality of outlets and a valve mechanismcoupling the outlets to the inlet in succession in response to changesin inlet fluid pressure. A distribution valve monitor includes aplurality of sensors disposed at spaced locations about the distributionvalve sensing different valve operating conditions. A controllercommunicates with the sensors and processes sensor output to detectoperation of the distribution valve deviating from desired distributionvalve operation.

According to yet another aspect there is provided a distribution valvecomprising an inlet receiving fluid from a fluid source, a plurality ofoutlets to deliver fluid to be distributed, a valve mechanism actuableto connect the outlet to the inlet in a desired sequence and a monitormonitoring operation of the valve mechanism and generating an alarmsignal when the valve mechanism malfunctions.

In one embodiment, the monitor generates the alarm signal upon jammingor skipping of the valve mechanism. The valve mechanism includes aplurality of spaced magnets thereon. The monitor detects thepresence/absence of the magnets to determine the operation of the valvemechanism.

The distribution valve monitor provides advantages in that operation ofthe distribution valve is recorded and stored. An alarm signal may begenerated when the distribution valve fails or malfunctions allowingdistribution valve failure to be determined without having to manuallycycle the inlet fluid pressure to the distribution valve and visuallymonitor the distribution valve output. The distribution valve monitor isalso easily installed on existing distribution valves without requiringsignificant modification of the distribution valve.

BRIEF DESCRIPTION OF THE DRAWINGS

An embodiment will now be described more fully with reference to theaccompanying drawings in which:

FIG. 1 is a schematic view of a conventional fluid distribution systemincorporating a mechanical liquid distribution valve (MLDV);

FIG. 2 is a side view of the MLDV and a distribution valve monitor in anunassembled condition;

FIG. 3 is a perspective view of the distribution valve monitor;

FIG. 4 is a schematic block diagram of the distribution valve monitor;

FIG. 5 is a side sectional view of the MLDV and distribution valvemonitor in an assembled condition; and

FIG. 6 is a cross-sectional view of FIG. 5.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Turning now to FIGS. 2 and 3, the mechanical liquid distribution valve(MLDV) 10 and a distribution valve monitor 50 are shown in anunassembled condition. Distribution valve monitor 50 monitors theoperation of the MLDV 10 so that failure or improper operation of theMLDV 10 can be recorded and used to signal an alarm condition dependingon the severity of the MLDV operating state.

The distribution valve monitor 50 comprises a sealed enclosure 52including three compartments, namely a battery and access compartment54, an electronics and plunger sensor compartment 56 and a rotationsensor compartment 58. The rotation sensor compartment 58 is generallytubular and is sized to accommodate the MLDV 10 so that the rotationsensor compartment 58, for the most part, surrounds the MLDV 10 with theelectronics and plunger compartment 56 sitting on top of the MLDV 10. Aliquid crystal display (LCD) 60 and a user actuable keypad 62 areprovided on the top surface of the electronics and plunger sensorcompartment 56 making the LCD 60 and keypad 62 readily available to auser.

FIG. 4 is a schematic diagram of the internal components of thedistribution valve monitor 50. As can be seen, the distribution valvemonitor includes a low power microcontroller 70 coupled to the LCD 60,the keypad 62 and a programming and interfacing connector 72.Programming and interfacing connector 72 is physically located withinthe battery and access compartment 54 and is accessible through removalof the lid 54 a of the battery and access compartment 54. A replaceablebattery 74 is also accommodated by the battery and access compartment 54and provides operating power to the internal components. Alternatively,the operating power may be provided via the programming and interfacingconnector 72 through an isolation switch 76. Microcontroller 70 samplesthe output of a plurality of hall effect sensors, namely a plungersensor 80 and rotation sensors 82 to 88. The sampled sensor output isprocessed by the microcontroller 70 and used to provide output to analarm relay 90 if an alarm condition exists. Alarm relay 90 is coupledto a dry contact 92 disposed within battery and access compartment 54via an isolation barrier 94. Dry contact 92 is electrically connected toan alarm panel (not shown) through a copper or fibre-optic link.

The microcontroller 70 and plunger sensor 80 are physically locatedwithin the electronics and plunger sensor compartment 56 with theplunger sensor 80 being disposed directly over the plunger 30 of theMLDV 10 (see FIGS. 6 and 7). The rotation sensors 82 to 88 arephysically located within the rotation sensor compartment 58 and aredisposed about the compartment at generally equal circumferenciallyspaced locations. The rotation sensors 82 to 88 lie in a plane thatcorresponds generally to the plane of the plate 32 of the MLDV 10.

FIGS. 5 and 6 best illustrate the positions of the plunger sensor 80 andthe rotation sensors 82 to 88 relative to the plunger 30 and plate 32 ofthe MLDV 10. In order to allow the plunger sensor 80 and rotationsensors 82 to 88 to detect the operational status of the MLDV 10, amagnet 100 is provided at the top of the plunger 30 and a magnet 102 isprovided on the plate 32 in line with the aperture in the plate 32. Aswill be appreciated, when the plunger 30 moves upwardly within the MLDV10 and brings the magnet 100 in close proximity to the plunger sensor80, the plunger sensor 80 generates a logic high output. When theplunger 30 is biased downwardly, the output of the plunger sensor 80returns to a logic low level. When the plate 32 rotates to bring themagnet 102 in close proximity to one of the rotation sensors 82 to 88,that rotation sensor generates a logic high output with the output ofthe remaining rotation sensors remaining at a logic low level. Themicrocontroller 70 samples the plunger and rotation sensor outputsthereby to collect actual MLDV operational data.

The microcontroller 70 includes non-volatile memory (not shown) so thatdata stored therein remains intact even in low and no power conditions.The non-volatile memory is programmed with desired MLDV operating data.The desired MLDV operating data is compared with actual MLDV operatingdata so that MLDV failure and/or malfunction can be detected. Inparticular, the operating data is examined to detect MLDV positioning,sequencing and/or timing errors. Data representing the elapsed time theMLDV 10 spends at each outlet position and all detected operationalerrors and malfunctions are also stored in the non-volatile memorythereby to keep historical data concerning the operation of the MLDV 10.

The operation of the distribution valve monitor 50 will now bedescribed. As mentioned previously, in normal operation of the MLDV 10,fluid pressure supplied to the inlet 12 of the MLDV 10 is cycledaccording to a desired fluid distribution sequence. Each time the fluidpressure supplied to the inlet 12 drops and then increases, the plunger30 and plate 32 reciprocate from a down position to an upwardly extendedposition before returning to the down position. During movement of theplunger 30 and plate 32 up and then back down, the plunger 30 and plate32 rotate thereby to bring the aperture therein into alignment with adifferent outlet 24 of the MLDV 10.

Each time the plunger 30 nears the top of its stroke, the magnetic fieldgenerated by the magnet 100 causes the plunger sensor 80 to output alogic high. The logic high condition is sampled by the microcontroller70 and stored allowing the microcontroller 70 to record the duration theplunger 30 remains at the top of its stroke as well as the elapsed timebetween each plunger reciprocation.

As the plate 32 rotates to bring the aperture therein into alignmentwith a different outlet 24, the magnet 102 is brought into proximitywith the rotation sensor associated with that outlet. The magnetic fieldgenerated by the magnet 102 causes the rotation sensor to output a logichigh. The logic high condition is sampled by the microcontroller 70 andstored allowing the microcontroller 70 to record the duration the plate32 remains in that position and hence the duration the inlet 12 iscoupled to that particular output.

The average time the MLDV 10 spends at each outlet is calculated. Ifdeviations in average time exist that are above a threshold levelsignifying failure and/or improper operation of the MLDV 10, an alarmsignal is generated. By measuring the elapsed time between strokes ofthe plunger 30 and the duration the plate 32 remains at each outletposition, the MLDV 10 can be monitored to ensure it cycles properly andis not jammed or skipping. Also by measuring the duration the plate 32spends at each outlet position, the MLDV can be monitored to ensurefluid is being distributed evenly to each outlet 24. Measuring theduration the plunger 30 remains at the top of its stroke allows stickingplunger conditions to be detected.

When MLDV jamming or skipping conditions are detected by themicrocontroller 70, the microcontroller generates an alarm signalcausing the alarm relay 90 to close thereby to provide the alarm signalto the alarm panel via the dry contact 92. Plunger sticking conditionsand deviations in the duration of the plate 32 at each outlet positionare recorded until the situations become severe at which time themicrocontroller 70 generates an alarm signal.

When the microcontroller 70 is not receiving input from the plungersensor 80 and rotation sensors 82 to 88, the microcontroller 70 isconditioned to a “sleep” mode to conserve power. The microcontrollerhowever switches to a “wake” mode either in response to activation ofone or more keys on the keypad 62 or a change in input received from oneof the plunger and rotation sensors.

The LCD 60 and keypad 62 provide a user interface that allows a user todetermine and view the operational status of the MLDV as well asrecorded data. In particular, through use of the keypad 62, the LCD 60can be conditioned to display the current operational status of the MLDVi.e. OK or Error, the status of the plunger sensor 80 and rotationsensors 82 to 88, the position of the plate 32, a menu of logged MLDVfailures/malfunctions and suggested causes as well as associated timesand dates.

The programming and interfacing connector 72 allows a reading device tobe coupled to the microcontroller 70 through an interface connector sothat stored data can be read and downloaded. The interface connectoralso allows a device to be coupled to the microcontroller 70 so that thedesired MLDV operating data can be updated.

The four (4) outlet MLDV is shown for illustrative purposes only. Aswill be appreciated, the distribution valve monitor can of course beused with MLDVs including fewer or more outlets. Although hall effectsensors in conjunction with magnets are used to sense movement of theplunger and plate, other non-contact sensing arrangements can of coursebe used.

The distribution valve monitor as illustrated is installed over anexisting MLDV with the MLDV being modified to include the magnets 100and 102. If desired, the distribution valve monitor and MLDV can beintegrated into a single unit to yield a distribution valve thatmonitors and records its operating status and generates an alarm signalin the event of failure and/or malfunction.

If desired, rather than using a physical connection between the drycontact 92 and the alarm panel and a physical connector 72 in thebattery and access compartment 54, the distribution valve monitor mayinclude one or more wireless transceivers to transmit alarm signals tothe alarm panel and/or to transmit recorded MLDV operating anderror/malfunction data to a remote station and to receive desired MLDVoperating data updates from the remote station.

Although preferred embodiments have been described, those of skill inthe art will appreciate that variations and modifications may be madewithout departing from the spirit and scope thereof as defined by theappended claims.

1. A distribution valve comprising: a housing having an internal fluidchamber; at least one inlet to permit the ingress of fluid into saidfluid chamber; a plurality of outlets to permit the egress of fluid fromsaid fluid chamber; a valve member in said fluid chamber, said valvemember carrying at least one position identifying element thereon, saidvalve member rotating and reciprocating in response to changes inpressure of fluid supplied to said at least one inlet; and a pluralityof non-contact sensors disposed at spaced locations about said fluidchamber to sense the presence of said at least one position identifyingelement at different positions within said fluid chamber.
 2. Adistribution valve according to claim 1 wherein said sensors are Halleffect sensors that detect the presence of magnets on said valve memberas the magnets move during rotation and reciprocation of the valvemember.
 3. A distribution valve according to claim 2 wherein said valvemember comprises a disc having a hole therein alignable with each outletin succession and a plunger on said disc, and wherein said sensorsinclude a plunger sensor to sense reciprocation of said plunger androtation sensors to sense rotation of said disc, and wherein said atleast one position identifying element comprises one magnet disposed onsaid plunger and another magnet disposed on said disc.
 4. A distributionvalve according to claim 1 wherein said sensors are arranged in a ringexternal of said fluid chamber.
 5. A distribution valve according toclaim 4 wherein said sensors are accommodated by a tubular housing thesurrounds the distribution valve housing.
 6. A distribution valveaccording to claim 1 further comprising a controller communicating withthe sensors and recording distribution valve operation data.
 7. Adistribution valve according to claim 6 wherein said sensors andcontroller are accommodated within an enclosure.
 8. A distribution valveaccording to claim 7 wherein said enclosure is shaped to receive saidhousing.
 9. A distribution valve according to claim 8 wherein saidsensors are Hall effect sensors that detect the presence of magnets onsaid valve member as the magnets move during rotation and reciprocationof the valve member.
 10. A distribution valve according to claim 9wherein said valve member comprises a disc having a hole thereinalignable with each outlet in succession and a plunger on said disc, andwherein said sensors include a plunger sensor to sense reciprocation ofsaid plunger and rotation sensors to sense rotation of said disc, andwherein said at least one position identifying element comprises onemagnet disposed on said plunger and another magnet disposed on saiddisc.
 11. A distribution valve according to claim 6 further comprising acommunications interface to enable recorded distribution valve operationdata to be downloaded to a remote location.
 12. A distribution valveaccording to claim 11 further comprising a user interface comprising adisplay to visually present distribution valve operation data.
 13. Adistribution valve according to claim 12 wherein said controllercompares recorded data with desired distribution valve operating data todetect improper distribution valve operation.
 14. A distribution valveaccording to claim 13 wherein said desired distribution valve operatingdata is programmable.
 15. A distribution valve according to claim 6wherein said controller examines recorded data to detect improperoperation of said distribution valve.
 16. A distribution valve accordingto claim 15 wherein said controller generates an alarm signal when thedistribution valve malfunctions.
 17. A distribution valve according toclaim 16 wherein said controller generates said alarm signal when saiddistribution valve jams or skips.
 18. A distribution valve according toclaim 17 further comprising a user interface comprising a display tovisually present distribution valve operation data.
 19. A distributionvalve according to claim 18 wherein said controller compares recordeddata with desired distribution valve operating data to detect improperdistribution valve operation.
 20. A distribution valve according toclaim 19 wherein said desired distribution valve operating data isprogrammable.
 21. A distribution valve monitor to monitor the operationof a distribution valve that comprises at least one inlet deliveringfluid to a housing having a fluid chamber therein, a plurality ofoutlets, and a valve mechanism in the fluid chamber and moveable toconnect each of the outlets to the fluid chamber in succession inresponse to changes in inlet fluid pressure, comprising: a tubularhousing removably receiving said distribution valve housing; a pluralityof sensors arranged in a ring and accommodated by said tubular housing,said sensors sensing the presence of at least one position identifyingelement on said valve mechanism at different positions within said fluidchamber; and a controller communicating with the sensors and recordingdistribution valve operation data.
 22. A distribution valve monitoraccording to claim 21 wherein said controller generates an alarm signalwhen the distribution valve malfunctions.
 23. A distribution valvemonitor according to claim 22 wherein said controller generates saidalarm signal when said distribution valve jams or skips.
 24. Adistribution valve monitor according to claim 21 further comprising auser interface comprising a display to visually present distributionvalve operation data.
 25. A distribution valve comprising: a housing; afluid chamber within said housing; at least one inlet receiving fluidfrom a fluid source and delivering the fluid to the fluid chamber; aplurality of outlets communicating with said fluid chamber to permit theegress of fluid from said fluid chamber and deliver fluid to bedistributed; a valve mechanism in said fluid chamber, said valvemechanism carrying at least one position indicator thereon and beingactuable in response to changes in pressure of fluid supplied to said atleast one inlet to connect said outlets to said at least one inlet in adesired sequence; and a monitor comprising a plurality of sensorsarranged in a ring surrounding said fluid chamber, said sensors sensingsaid at least one position indicator at different positions in saidfluid chamber.
 26. A distribution valve according to claim 25 whereinsaid monitor generates an alarm signal upon jamming or skipping of saidvalve mechanism.
 27. A distribution valve according to claim 25 furthercomprising a user interface comprising a display to visually presentdistribution valve operation data.
 28. A distribution valve according toclaim 27 further comprising a communications interface to enablerecorded distribution valve operation data to be downloaded to a remotelocation.